Thermoplastic polyurethane as a base material for soft, high-density neural interfaces
Polymers used as substrate and encapsulation for implantable devices are typically deposited layer-by-layer, leaving polymer-polymer interfaces that adhere poorly and become a critical failure point. Thermoplastic polyurethane (TPU) elastomers combine four properties not found together in any other candidate: decades of clinical use in long-term implants and availability in medical grade, a stiffness well below that of polyimide and parylene C, compatibility with microfabrication, and thermoplastic self-fusion, which removes the polymer-polymer interface entirely. This work introduces TPU as a base material for soft, high-density neural interfaces and demonstrates one route to realizing them. Gold is patterned on a sacrificial copper sheet by maskless lithography and transferred into TPU by vacuum lamination, giving conformally coated tracks down to 15 um at 30 um pitch within a single, merged polymer body. An additional electroplating step produces a nanostructured pinecone gold surface that increases the electrochemically active area of the electrodes, approximately doubling the charge injection capacity. Daisy-chain silicon chips were also embedded within the soft polymer body. The films transmit up to 88% at 470 nm, a wavelength commonly used for optogenetics. TPU showed no cytotoxicity towards differentiated SH-SY5Y cells and only a mild tissue response after 9.5 months of subcutaneous implantation in rats.